Quiet on the blog but it has been busy in the workshop with a number of projects progressing. My VSCCS application has been approved in NSW and I am just waiting on a response from the WA Department of Transport. And the picture? Well one of the projects in progress is a rebuild of a 1974 Honda QA50. This is the engine casing after a quick bead blasting.
A recent inspection on a Holden Commodore revealed that the power steering cooler was leaking. The standard cooler is a length of 3/8″ steel tube running horizontally in front of the radiator. These are known for rusting and splitting or leaking fluid. Below is a close up of the part that was removed.
After using a popular “blender” for approximately nine months the blades no longer span as fast (audibly) and there would be a faint burning rubber smell after use. When the manufacturer was contacted I was informed that the base with the blades was a consumable item and they expected them to be replaced every six months. Continue reading Badly Engineered or Good Marketing?→
As mentioned previously on this blog, this is a motard style conversion of a Honda CRM 250 using a 2007 model Aprilia RS-125 wheels, discs and front brake caliper.
A custom bracket was designed in Solidworks to adapt the radially mounted caliper to the original brake caliper mounting holes. Designing in 3D allowed the part to be simulated (FEA) with heavy braking loads and calculate the factor of safety, stress, strain and distortion.
The APRILIA RS-125 caliper has finally been installed on the Honda CRM-250. The brake system has been bled with a quality DOT-4 brake fluid. It now has a solid feel (though there is some sponginess due to brake hose expansion – this may be replaced with a braided line) and no leeks in the system. So far low-speed testing has been carried out with further testing to come.
This was a practical application of using 3D-printing to fabricate replacements for obsolete parts. The center caps for Holden Commodores with steel rims is a good addition to crate a tidy standard looking vehicle. These parts were commonly available and many were probably thrown away when steel rims were upgraded to alloy wheels but now a set can be from $100 – $180. Continue reading Replacing Obsolete Parts→
With the development of so many consumer, DIY and kit CNC mills, lathes, Laser-cutters, 3D-printers and other assorted NC machines that line our wishlists it can be easy to forget that a lot can be accomplished with manual tooling.
The calipers have been dis-assembled and inspected. The castings of the inner and outer caliper halves are symmetrical, front to rear, and could be machined to suit either the left or right hand side fork of the motorbike.